41 31 001 Replacing roof outer skin (version with slide/tilt sunroof)

Special tools required:

41 3 010

Read contents of BODY, GENERAL .

STRIP DOWN vehicle.

Observe procedure for REPAIR STAGE 2

After completing work:

Remove excess adhesive in the entire adhesive area.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive area with sealant D1.

Carry out a leak test on entire vehicle.

The following new body parts are required:

(1) Roof outer skin, panorama glass roof

The following CONSUMABLES are required:

Fig 1: Identifying Panorama Glass Roof Outer Skin

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MATERIAL QUANTITY SPECIFICATION

Material	Quantity
Adhesive K5b	2
Blind rivets N3	4
Punch rivets N4	37
EMC screws	2
Cleaning agent R1	1
Structural foamHS2	1
Sealant D1

Removing roof outer skin

Open welding spots in areas (1).

Open weld seams in areas (2).

Open brazed seam in area (3) by grinding.

Fig 2: Identifying Welded Spot Areas, Welded Seam Areas, And Brazed Seam Area

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Open bonded connection in area (1).

Fig 3: Identifying Bonded Connection Area

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Take off roof outer skin.

Open welding spots in area (1).

Fig 4: Identifying Area Of Welded Spots

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New part preparation

Follow the procedure for vehicles with ROOF RAILS !

Cut all four roof rack reinforcements (1) along lines (2).

IMPORTANT: Do cut not roof outer skin (3).

Fig 5: Identifying Roof Rack Reinforcement, Cutting Areas, And Roof Outer Skin

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Operation is described on the left side. Right side identical.

Adjust roof outer skin to fit and secure.

Set two 4.2 mm dia. holes for blind rivets in areas (1).

Remove new part again and deburr bore holes.

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Fig 6: Identifying Areas For Blind Rivet Bore Holes

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Installing roof outer skin

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive in areas (1) and (2).

Fig 7: Identifying Adhesive Application Areas

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Apply adhesive in areas (1).

Fig 8: Identifying Adhesive Application Areas

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Apply D1 sealant in areas (1) in the same way as in series standard.

Fig 9: Identifying Sealant Application Areas

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Operation is described on the left side. Right side identical.

Mount roof outer skin and rivet with blind rivets (1).

Fig 10: Identifying Areas For Blind Rivets

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In area (1) rivet roof outer skin with 7 punch rivets.

Fig 11: Identifying Area For Punch Rivets

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In area (1) rivet roof outer skin with 11 punch rivets.

Fig 12: Identifying Area For Punch Rivets

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In area (1) rivet roof outer skin with 8 N4 punch rivets.

Fig 13: Identifying Bonded Connection Area

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Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant.

IMPORTANT: In order to achieve the required flow behavior of the foam in the cavity, a cartridge temperature of approx. 65 °C to 70 °C is required.

WARNING: Risk of scalding!

Lay 2 cartridges in a heat-resistant container and weight down.

Filling container with approx. 3 liters boiling water.

Insert cartridges for approx. 30 minutes.

Insert heated adhesive cartridge shortly before processing in cartridge gun 41 3 010 , remove cap and allow both components to emerge. Wipe adhesive components uniformly and attach new mixing tube.

Tip of fill level indicator (1) indicates the current position of the plunger.

For optimum mixing of components, allow structural foam to emerge up to marking (2) and discard.

Fig 14: Identifying Fill Level Indicator

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Fill all 4 areas of roof rack reinforcements with foam.

(1) Threaded inserts

Starting at front left, fill square holes (2) with 75 ml of structural foam each.

In so doing, hold mixing tube at an angle of approx. 30°.

Immediately after applying foam, press expansion nuts into square holes.

Repeat procedure on right side of car with second cartridge.

Operational strength of car is achieved after 24 hours.

Fig 15: Filling Areas Of Roof Rack Reinforcements With Foam

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After hardening of the adhesive install two EMC SCREWS in area (1).

Fig 16: Identifying Installation Area For EMC Screws

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